Sun visor and cover attachment method

ABSTRACT

The sun visor has a decorative cover securely affixed over a core formed of foldable first and second core halves. Receiving surfaces defining a planar end are formed on each of the first and second core halves and extend substantially continuously between opposed ends. The edges of the cover are folded over onto the receiving surfaces and fixed to the receiving surfaces

BACKGROUND

[0001] The present invention relates, in general, to vehicle sun visors.

[0002] Sun visors are used in vehicles to provide front and side windowprotection from sunlight entry. Such sun visors are pivotal about alongitudinal axis between a stowed position adjacent the headliner and adeployed position angularly extending from the headliner. Most sunvisors can also be unlocked from a headliner mounted clip or D-ring andpivoted to the side window about a support arm attached to the vehicleheadliner. A biasing means is typically mounted within the visor toprevent movement and noise when the sun visor is in the stowed position.

[0003] Over the years, various enhancements or features have been addedfor sun visors to increase their versatility as well as to add otherconvenience factors to the vehicle occupants.

[0004] One such feature is the telescopic extension of the entire sunvisor along the longitudinal axis of the support arm to enable the sunvisor to be repositioned laterally across the windshield or the sidewindow to block sun light entry in a particular direction for anoccupant.

[0005] Another common feature is a mirror with or without a pivotalcover and with or without an illumination means which is mounted in onesurface of the sun visor, typically the surface facing the headlinerwhen the sun visor is in the stowed position. The sun visor need only bepivoted to the angular downward extending position to allow use of themirror.

[0006] When an illumination means, such as lamps, are provided aroundthe mirror, electrical conductors or wires extend through the A pillarof the vehicle body and the support arm to the individual lamps in thesun visor.

[0007] Various means have been provided to mount fabric or decorativecovers over the plastic sun visor core. One such mount traps the ends ofthe fabric cover between the two clam shell core halves when the halvesare moved to their closed, locked position. Another mount utilizesprojections on the inner surfaces of the core halves over which theinner edges of the fabric cover are forced.

[0008] Heat stake projections have also been provided about theperiphery of the core halves. In this mounting technique, the edges ofthe fabric cover are forced over the heat stake projections and thenheat is applied to melt the stakes through the interstices of the fabriccover to fixedly retain the inner edges of the cover in a fixed positionon the sun visor core.

[0009] Despite the improvements which have been made to vehicle sunvisors, it would still be desirable to provide an improved sun visorwhich is easier to manufacture, have a more pleasing exterior aestheticappearance, can be manufactured at a lower cost, and has improved buzz,squeak and rattle control features.

SUMMARY

[0010] The present invention is a sun visor having a unique decorativeor outer fabric cover attachment structure and method.

[0011] In one aspect, the inventive method includes the steps of forminga core with first and second core halves oppositely extending from acommon hinge edge. The method also includes forming a receiving surfaceon each of the first and second core halves spaced from a periphery ofthe first and second core halves. The method further includes the stepof overlaying the core over a cover with the edge portions of the coverfolded over the peripheral edges of the first and second core halvesinto engagement with the receiving surfaces on the first and second corehalves. Finally, the edges of the cover are joined to the receivingsurfaces.

[0012] In another aspect, the method further includes the step offorming the receiving surface on at least one of the first and secondcore halves in the form of a continuous surface. The continuous surface,in one aspect, has a planar end.

[0013] The receiving surfaces in the first and second core halves arepositioned to overlay each other when the first and second core halvesare moved to the closed, assembled position.

[0014] The present invention also defines a sun visor including a corewith the first and second foldable core halves, and a receiving surfaceon each of the first and second core halves spaced from a periphery ofeach of the first and second core halves. A cover has edges folded overthe periphery of the first and second core halves and heat joined to thereceiving surfaces on the first and second core halves.

[0015] In one aspect, the receiving surface in each of the first andsecond halves defines a continuous surface between opposed ends.

[0016] In one aspect, the receiving surface defines a planar end raisedfrom the plane of a major portion of each of the first and second corehalves. In another aspect, the receiving surfaces in the first andsecond core halves overlay each other in alignment when the first andsecond core halves are folded together into a closed, assembledposition.

[0017] The cover attachment structure and method of the presentinvention provides a secure cover attachment to a sun visor core over asubstantially continuous portion of the peripheral edges of the two corehalves. This insures a more secure and smoother attachment of the coverto the core as compared to the typical prior art use of spacedprojections or spikes in the core halves over which the fabric cover isforcibly urged and then heat welded together.

BRIEF DESCRIPTION OF THE DRAWING

[0018] The various features, advantages and other uses of the presentinvention will become more apparent by referring to the followingdetailed description and drawing in which:

[0019]FIG. 1 is a perspective view of a completely assembled sun visoraccording to one aspect of the present invention;

[0020]FIG. 2 is an elevational view of an open clam shell core for thesun visor shown in FIG. 1, depicting the initial step of attaching thefabric cover to the core;

[0021]FIG. 3 is an enlarged, cross-sectional view of one corner of theclam shell core in the closed position showing the edge fold and edgematerial attached to the core;

[0022]FIG. 4 is an enlarged, perspective view of the corner of the coreshown in FIG. 3;

[0023]FIG. 5 is an exploded, perspective view of the slide carrier, clipand large support rod according to one aspect of the present invention;

[0024]FIG. 6 is a cross sectional view showing the slider carrier, clipand support rod in a closed core position;

[0025]FIG. 7 is a perspective view of the sun visor of FIG. 1 depictingthe slider means in the normal, retracted position;

[0026]FIG. 8 is a perspective view similar to FIG. 7, but showing theslide carrier in the fully extended sun visor position;

[0027]FIG. 9 is a perspective view of the sun visor of FIG. 1 having ashort length, non-telescoping support arm;

[0028]FIG. 10 is a perspective view of another aspect of the sun visoraccording to the present invention shown in an open core position anddepicting the mounting of a mirror to one core half;

[0029]FIG. 11 is a perspective view of a completed sun visor showing oneaspect of a fully optioned mirror assembly with a cover deployed in aclosed position;

[0030]FIG. 12 is a perspective view, similar to FIG. 11, but with thecover deployed in an open position;

[0031]FIG. 13 is a cross-sectional view through the sun visor of FIG. 11depicting the mounting of the mirror assembly to the core and cover;

[0032]FIG. 14 is a perspective view of another aspect of a sun visoraccording to the present invention having a mirror assembly mountedtherein; and

[0033]FIG. 15 is a cross-sectional view of an alternate aspect of thesun visor of the present invention.

DETAILED DESCRIPTION

[0034] Referring now to the drawings, and to FIGS. 1-14 in particular,there is depicted a sun visor denoted generally by reference number 10which includes a number of features, all described hereafter, which maybe used in various combinations as well as individually, separate fromthe other features.

[0035] In general, the sun visor 10 includes a core 12, a cover 14typically made of fabric, including synthetics and natural fabrics, asupport arm formed of either a long length support arm 16 allowingtelescoping movement of the sun visor 10 as described hereafter and asshown in FIGS. 7 and 8 or a short length support arm 18 shown in FIG. 9which does not provide telescoping extension of the sun visor 10. Thesun visor 10 may also include a mirror assembly shown in various featurecombinations in FIGS. 11-14.

[0036] Referring now to FIGS. 2-4, the core 12 is in the form of a clamshell having a first clam shell portion or half 20 and a second portionor half 22. The core 20 is formed of a suitable, light weight, easilyformed material, such as plastic. A plastic useable to form the core 12maybe polypropylene, by example only.

[0037] The first and second core halves 20 and 22 are integrally andpivotally joined together along a living hinge portion or edge 24extending between one longitudinal edge of each of the core halves 20and 22.

[0038] The core halves 20 and 22 have a substantially mirror imageconfiguration formed of opposed longitudinal edges joined together toform the living hinge 24, outer longitudinal edges 26 and 28, adjacentside edges 30 and 32, and adjacent side edges 34 and 36. The side edges26 and 28 may optionally be formed as part of a pivotal flap sectionpivotable about a second living hinge or weakened portion 38 formedadjacent from each side edge 26 and 28.

[0039] As shown in FIGS. 1 and 2, an intermediate portion between theside edges 30 and 32 and an intermediate portion 40 between the sideedges 30 and 32 of the first and second core half 26 and 28,respectively, is recessed to form a space for insertion of one supportarm 16 or 18 into the core 12. An end portion of the living hinge 24between the core halves 26 and 28 is formed with an aperture 42 which,when the core 12 is in the closed, fully assembled position shown inFIG. 1, defines an open ended recess adapted for receiving a D-ring 44for securing one end of the sun visor 10 to a latch member mounted in avehicle head liner, not shown. The D-ring 44 is mounted in the core 12by suitable clips, not shown.

[0040] The core 12 of the present invention is provided with a uniquecover mounting means which insures a quick and secure mounting of thecover 14 on the outer surface of the core 12.

[0041] The cover mounting means includes an elongated, elevated coverattachment surfaces 50 and 52 respectively formed in the core halves 20and 22. Each surface 50 and 52 is formed as one elongated projectionextending between the side edges 30 and 34 and the side edges 32 and 36or in a discontinuous fashion formed of multiple segments orprojections. Each surface 50 and 52 terminates in a suitably formedouter mounting surface 54 and 56, respectively. Each surface 54 and 56may be planar or have any other shape, such a smoothly curved concave orconvex shape.

[0042] In the aspect of the surfaces 50 and 52 shown in FIGS. 2 and 3,each surface 50 and 52 has a generally C-shape, formed as a continuousmember projecting outward from the main extent or plane of the corehalves 20 and 22.

[0043] In attaching the cover 14 to the core 12, the core 12 and thecover 14 are juxtaposed as shown in FIG. 2 with cover 14 overlaying anouter surface of the core 12. In this arrangement, the outer peripheraledge of the cover 14 shown by reference number 58 projects outwardbeyond the periphery of the side edges 30, 32, 34 and 36 of the core 12.The outer peripheral edge 58 of the cover 14 is then folded over aperipheral lip 60 and 62 on each core half 20 and 22 and inward to aposition in which the peripheral edge 58 of the cover 14 is in contactwith and overlays each of the surfaces 54 and 56 on the surfaces 50 and52. Sonic waves are then applied to the surfaces 50 and 52 to causemolecular vibration and melting of the surfaces 50 and 52 into theinterstices of the cover thereby joining the cover 14 to the core halves20 and 22, after cooling, in a secure connection or joint which extendssubstantially continuously about the entire periphery of the core 12.

[0044] As shown in FIGS. 2-4, alignment and stability enhancing members70, 72, 74 and 76 are formed in complimentary positions in the corehalves 20 and 22 so as to be disposed in close proximity with an opposedmember, with contact also being possible, as shown in FIGS. 3 and 4,when the core halves 20 and 22 are folded into the closed, fullyassembled position. The alignment members 70, 72, 74 and 76 may take anyshape, with the generally angular, L-shape shown in FIG. 2 by way ofexample only.

[0045] Lock means are provided for securing locking the core halves 20and 22 in a fully assembled, closed position shown in FIGS. 3 and 4. Thelock means comprises a plurality of posts denoted generally by referencenumber 80 which are formed of a stem 82 and a head 84 having a radiallyoutward extending periphery formed of at least two side arms 86 and 88.Rather than just two side arms 86 and 88, the entire periphery of thehead 84 may be enlarged to a greater diameter or cross-section dimensionthan the diameter or cross-section of the stem 82 so as to provide anenlarged head which overhangs the outer periphery of the stem 82 asshown in FIG. 3. The posts 80 are deployed at a number of locations onone of the core halves 20 and 22, with the post 80 being shown by way ofexample only as being mounted on the core half 22.

[0046] A plurality of lock receivers 90 are formed in the other corehalf 20. The lock receivers 90 include an outer wall formed of at leasttwo wall portions 92 and 94, with additional wall portions, including athird wall portion and even a fourth wall portion to form walls 92, 94,96 and 98 as a completely closed, continuous wall may also be employed.Lock members are resiliently mounted on and extend from an end of atleast two of the side walls 92 and 94. The lock members all denotedgenerally by reference number 96 include a leg 98 which terminates in anouter end 100. The legs 98 of the lock members 96 are disposed at anacute angle from the adjacent side wall 92 or 94 such that the outer end100 is pivotal about the connection between the legs 98 and the adjacentside walls 92 and 94 of each receiver 90. This pivotal movement allowsthe head 84 of a complementarity positioned lock post 80 on the matingcore half 22 to slide through the space normally existing between twoadjacent lock legs 96 thereby urging the outer ends 100 outward untilthe head 84 snaps past the outer ends 100 of the legs 98. The legs 98then snap back toward the nominal position and seat against a shoulderformed between the inner surface of the sides 86 and 88 of the head 84and the adjacent outer surface of the stem 82 thereby securely lockingthe lock post 80 in the receiver 90. The same locking process occursacross the entire core 12 at every location of a matingly positionedreceiver 90 and lock post 80.

[0047] Referring again to FIGS. 1 and 2, and in greater detail in FIGS.5 and 6, the support arm 16 is mounted within the core 12 prior tolocking closure of the core halves 20 and 22 as described above. Thesupport arm may take one of two configurations, including thetelescoping, long length support arm 16 shown in FIGS. 7 and 8 and theshorter length support arm 18 shown in FIG. 9 for non-telescoping sunvisors.

[0048] Regardless of the length of the support arm 16 or 18, the endportion of each support arm 16 or 18 includes at least one andpreferably a pair of flats 110 adjacent an outer end 112, with only thesupport arm 16 being depicted in FIG. 5 by way of example only. Theremainder of the support arm 16 may have a circular cross-section, byexample only. A stop flange 114 is spaced from the end 112 of thesupport arm 18 to retain the support arm 18 in a slide carrier 120. Thecarrier 120 defines an integral, one piece body, typically of a moldedplastic, having a pair of side arms 122 and 124, each with an aperture126 and 128, respectively, the apertures 126 and 128 being coaxiallyaligned for receiving the end portion of the support arm 18 with theflats 110 disposed between the side arms 122 and 124.

[0049] A first pair of apertures 130 are formed in a central leg 132 ofthe slider 120. A second pair of apertures 134 are also formed in thecentral leg 132 of the slider 120. The pairs of apertures 130 and 134receive bent edges 136 and 138 of a spring clip 140 to attach the springclip 140 to the slider 120. The spring clip 140 has an enlarged endportion denoted by reference number 142 which receives the end portionof the support arm 16. A pair of bent portions 144 and 146 on the springclip 140 resiliently engage the flats 110 on the end of the support arm18 to exert a biasing force tending to retain the entire sun visor 10 ina fixed position, typically biased in a direction toward the vehicleheadliner in a normal, stored sun visor position to minimize buzz,squeaks or rattles. This provides the necessary noise control featuresfor the sun visor 10 of the present invention.

[0050] The sun visor 10 has a unique telescoping mount using the slidecarrier 120 which may be used by itself or in combination with the heatstake cover attachment described above as well as with or without any ofthe additional unit features of the sun visor described hereafter.

[0051] The slide carrier 120 includes first and second, oppositelydirected, open ended channels 150 and 152 which are integrally formed inthe carrier 120. The open end of the channel 150 extends oppositely fromthe open end of the channel 152. The channels 150 and 152 are positionedto engage slide rails 154 and 156, shown in FIGS. 2, 6, 7 and 8 whichare integrally formed as part of the core halves 20 and 22,respectively. The slide rails 154 and 156 extend along the length ofeach core half 20 and 22, generally in parallel with the hinge 24.

[0052] When the core halves 20 and 22 are locked in the fully assembled,closed position shown in FIG. 6, the slide rail 154 engages the channel150 and the opposed slide rail 156 engages the opposite channel 152 inthe slider 120. This dual, opposed slide rail and channel configurationsecurely retains the slider 120 in a constant orientation during alltelescoping movement of the sun visor 10 relative to the support arm 16as described hereafter. The addition of the second channel 150 and theslide rail 154 provides added stability to insure a smooth, evenbi-directional telescoping movement of the sun visor 10 along thesupport arm 16 while at the same time securely retaining the sun visor10 to the support arm 16.

[0053]FIG. 7 depicts the normal, non-telescope position of the sun visor10 relative to the support arm 16. In this position, the carrier 120 isdisposed adjacent to the D-ring end of the sun visor 10. When thevehicle occupant desires to laterally extend the position of the sunvisor 10 relative to the support arm 16, the occupant grasps the sunvisor 10 and slides the sun visor 10 along the support arm 16 to anyposition up to a maximum extend position shown in FIG. 8. In the maximumextended position, the carrier 120 is disposed adjacent to a support armpivot support or clip 160. The clip 160, shown in FIGS. 7, 8 and 9,includes a wall integrally formed on one of the core halves, such as thesecond core half 22 having an aperture 162 for receiving the support arm16 therethrough. The portion 164 of the wall 160 carrying the aperture162 is spaced from a collar 166, also formed on the core half 22, whichdefines a generally circular cross-section bore through which thesupport arm 16 extends.

[0054] The sun visor 10 may also be provided with the short lengthsupport arm 10 for non-telescoping use without any modifications to thecore 12. By example only, the non-telescoping aspect of the present sunvisor 10 also employs the carrier 120, the support wall 160 and thesleeve 166. However, the carrier 120 is non-laterally moveably disposedwithin the wall 160 as shown in FIG. 9.

[0055] Referring now to FIGS. 10-14, there is depicted several aspectsof a mirror assembly which may be optionally employed with the sun visor10 of the present invention. It will be understood that the variousaspects of the mirror assembly described hereafter are useableindependently or in combination with any of the telescoping, fabriccover mount or core lock means described above.

[0056] In one aspect of a mirror assembly shown in FIG. 10, whichpreferably applies to all the mirror assemblies described hereafter, ashallow recess 170 is formed in the core half 22 projecting slightly outof the plane of the main extent of the core half 22. The recess 170 isformed by a wall 172.

[0057] At least one and preferably a plurality of spaced apertures 174are formed in the wall 172. Each aperture 174 is alignable with acorresponding lock receiver 90 on the mating core half 20. Each aperture174 is positioned to receive a lock post 80, identical to the lock post80 described above for locking the core halves 20 and 22 in the fullyclosed, assembled position, but now provided on a back plate 176 of aframe or mirror support. The lock posts 80 project from the back wall orplate 176 so as to extend through the apertures 174 and the wall 172 andinto locking engagement with the mating receiver 90 when the core halves20 and 22 are pivoted to the fully closed position. This enables themirror assembly to be fixedly attached to the core 10 at the same timethe core halves 20 and 22 are locked in the closed, fully assembledposition.

[0058]FIGS. 11 and 12 depict an opposite surface of the core half 22which has the recess 170 formed therein for receiving a mirror assembly182. In this aspect of the mirror assembly 182, the mirror assembly 182includes a moveable or pivotal cover 184 which is pivotally mounted to aframe 186 formed of a fixed frame member 188 attached to the back plate176 shown in FIG. 10 and a mirror surround frame 190, only a portion ofwhich is shown in FIG. 11. The cover 184 has a generally planar extent,with depending side walls and a raised edge 192 to permit easy pivotalmovement of the cover 184 between open and closed positions shown inFIGS. 12 and 11, respectively. A hinge 189 is provided between a fixedframe element 188 and the cover 184.

[0059] The mirror assembly 182, as shown in FIG. 12, also is providedwith an illumination means in the form of one or more lamp means 196 and198 mounted in the mirror surround frame 190 on at least one andpreferably opposed sides of a reflective mirror 200. The mirror 200 istypically adhesively joined to the back plate 176. Conductors forconducting power to the light means 196 and 198 located below thebezzles or lenses 202 are routed between the closed core halves 20 and22 and into an aperture formed in the support arm 16 or 18 whereby thewires exit the sun visor 10 and pass through the vehicle interior,typically through the vehicle A pillar to the accessory power vehiclecircuit.

[0060] According to a unique aspect of the present invention, the mirrorassembly 182 is mounted on the sun visor 10 after the core halves 20 and22 of the sun visor 10 have been pivoted to the closed, latchedposition. As shown in FIG. 13, the lock post 80 may be forced throughthe fabric cover 14 into the underlying receiver 90 to fixedly mount themirror assembly 182 to the sun visor 10. The layer of the cover fabric14 disposed between the back wall 176 of the mirror assembly 182 and thecore half 20 minimizes the generation of buzzes, squeaks and rattles.

[0061] It will be understood that the mirror assembly 182 may beprovided without the lamp means 196 and 198 and with or without thepivotal cover 184. Another mirror assembly 210 is depicted in FIG. 14.In this aspect, the mirror apparatus is formed of a multi-sided frame212 which surrounds a mirror 214 secured, typically by adhesive, to aback plate, not shown. The back plate can be identical to the back plate176 so as to carry the lock posts 80 for secure attachment of the mirrorassembly 210 to the core half 22 as described above.

[0062] As shown in FIG. 15, the core 10 having the recess 172 formed inone of the core halves for receiving one of the mirror assembliesdescribed above, may also be utilized without any mirror assemble. Inthis application, a filler member 220 has a peripheral shapecomplementary to the shape of the recess 170 in the core half 22 and athickness substantially the same as the depth of the recess 170.

[0063] In use, the filler member 220 is mounted within the recess 170and covered by the cover 14 which holds the filler member 220 in therecess 170. Alternately, the filler member 220 may be fixed in therecess 170 by means of adhesive, etc.

[0064] The use of the filler member 220 provides a flush surface withthe surrounding surface of the core half 22 when a mirror assembly isnot used in the sun visor 10. At the same time, the filler memberenables a single core 12 design to be employed with and without a mirrorassembly without requiring any modification or additional manufacturingcost.

[0065] In summary, there has been disclosed a unique vehicle sun visorhaving improved fabric cover attachment, easy and reliable telescopingvisor movement, the option to switch between a telescoping support armand a fixed short support arm without modification to the sun visor coreso as to contribute to a reduced manufacturing cost, multiple mirrorassembly mounts, unique and reliable core lock members, and a mirrorattachment means which controls or minimizes the generation of noisebetween the contacting parts of the mirror and the sun visor core.

What is claimed is:
 1. A method of manufacturing a sun visor comprisingthe steps of: forming a core with first and second core halves extendingoppositely from a common hinge; forming a receiving surface on each ofthe first and second core halves spaced from a periphery of the firstand second core halves; overlaying the core over a cover with edgeportions of the cover extending beyond the periphery of the core halves;folding peripheral edge portions of the cover over peripheral edges ofthe first and second core halves into contact with the receivingsurfaces on the first and second core halves; and fixing the edges ofthe cover to the receiving surfaces.
 2. The method of claim 1 whereinthe step of forming the receiving surfaces comprises: forming thereceiving surfaces on at least one of the first and second core halvesas a continuous surface between opposed ends of the receiving surface.3. The method of claim 2 further comprising the step of: forming anouter end of each receiving surface as a planar surface.
 4. The methodof claim 1 wherein the step of forming the core further comprises:forming each of the first and second core halves with opposed sidesextending from the common hinge edge, and one longitudinal edge spacedfrom the common edge; and forming the receiving surface on each of thefirst and second core halves along the opposed side edges and thelongitudinal edge.
 5. The method of claim 1 further comprising the stepof: forming the receiving surfaces in the first and second core halvesin a spatial relationship so that the receiving surfaces on the firstand second core halves overlay each other in substantial alignment whenthe first and second core halves are folded together about the commonhinge edge.
 6. A sun visor constructed in accordance with the method ofclaim
 1. 7. A sun visor comprising: means for forming a core with firstand second core halves extending oppositely from a common hinge; meansfor forming a receiving surface on each of the first and second corehalves spaced from a periphery of the first and second core halves;means for overlaying the core over a cover with edge portions of thecover extending beyond the periphery of the core halves; means forfolding peripheral edge portions of the cover over peripheral edges ofthe first and second core halves into contact with the receivingsurfaces on the first and second core halves; and means for joining theedges of the cover to the receiving surfaces.
 8. The sun visor of claim7 wherein: the receiving surface on at least one of the first and secondcore halves extends continuously between opposed ends.
 9. The sun visorof claim 7 further comprising: a hinge formed at a common edge betweenthe first and second core halves.
 10. The sun visor of claim 9 furthercomprising: each of the first and second core halves defined by opposedside edges extending from the common edge and one longitudinal edgeextending between the opposed side edges and spaced from the commonedge; and the receiving surfaces in each of the first and second corehalves extending along the opposed side edges and the longitudinal edge.11. The sun visor of claim 7 wherein: the receiving surface in at leastone of the first and second core halves defines a planar surface raisedfrom a plane extending through a major extent of at least one of thefirst and second core halves.
 12. The sun visor of claim 7 furthercomprising: the receiving surfaces in the first and second core halvesdisposed in an overlaid, spatial relationship when the first and secondcore halves are folded together about the common edge.